Method of manufacturing a laminated planar structure

ABSTRACT

A method of making an integral laminated planar structure such as a map having a total information content composed of general information and specialized information, characterized by preparing a planar first layer containing the general information; preparing a photographic reproduction overlay containing the specialized information; and accurately aligning and bonding the photographic reproduction overlay and the planar first layer. The photographic reproduction overlay is transparent except for the specialized information it contains so as to expose the general information contained on the planar first layer.

July l1, 1972 G. w. PLUMLY 3,676,241

METHOD OF MANUFACTURING A LAMINATED PLANAR STRUCTURE Filed Dec. 17, 1969 2 Sheets-Sheet l TREN TON CAMDEN l' l' TRE/v To/v July l1, 1972 G. w. PLUMLY 3,676,241

METHOD 0F MANUFACTURING A LAMINATED PLANAR STRUCTURE Filed Dec. 1'7, 1969 2 Sheets-Sheet 2 /NVE/VTOR United IStates Patent O 3,676,241 METHOD F MANUFACTURING A LAMINATED PLANAR STRUCTURE George W. Plumly, 3900 Tamworth Road, Fort Worth, Tex. 76116 Filed Dec. 17, 1969, Ser. No. 885,755

Int. Cl. B29j 1 00 U.S. Cl. 156-62 16 Claims ABSTRACT 0F THE DISCLOSURE BACKGROUND OF THE INVENTION (l) Field of the invention This invention relates to a method of forming integral laminated planar structures such as maps having a total information content composed of general information and specialized information.

(2) Description of the prior art It is known in the prior art to assemble general and specialized information on a planar structure and duplicate the resulting structure. The duplication of the resulting structure may be by printing or other means. Such assembly is successful if even the specialized information is still widely used so that the expense can be pro rated over a large number of purchasers. Where specialized information is very specific and of interest to only a limited number of purchasers, the cost per unit is so great as to be economically infeasible, ordinarily.

BRIEF DESCRIPTION OF THE DRAWINGS FIG. l is a partial plan view of a repeatedly used photographic positive of an art work employed in one stage of one embodiment of this invention.

FIG. 2 is a partial-plan view of a photographic negative of the photographic positive of =FIG. l after erasure of lead lines and codification of cities.

FIG. 3 is a partial plan view of a list containing city code numbers and respective mileages therefrom to a predetermined city for use in connection with the photographic negative of FIG. 2.

IFIG. 4 is a partial plan view of a sheet of transparent material having the respective mileages emplaced thereon in correlation with the respective blanks of the negative of FIG. 2.

FIG. 5 is a partial plan view of a finished photographic reproduction overlay begun as illustrated in FIG. l.

FIG. 6 is a partial perspective 'View of a map, a photographic reproduction overlay, and apparatus employed in effecting final assembly of one embodiment of this invention.

FIG. 7 is a partial plan view of a finished map containing general information, widely useful specialized information and specific specialized information.

vlFIG. 8 is a partial plan view of a card used in one embodiment of this invention.

3,676,241 Patented July 11, 1972 It is a primary object of this invention to produce integral laminated planar structures such as maps containing both general and specialized information so economically as to be practical even with a limited market.

It is a specific object of this invention to employ economical photographic processes in combination with overlays having information of varying degrees of general interest to enable pseudo mass production techniques to be employed in economically and feasibly producing integral laminated planar structures such as maps containing both general and specialized information.

While the invention, in one or more of its aspects, may be broadly useful; the following preferred embodiment will be described with respect to a map containing general information and specialized information and a method of manufacturing the map. In manufacturing, or making, the map containing general information and specialized information, a basic map is first prepared containing the predetermined general information. Next, a photographic reproduction overlay containing the specialized information is prepared. Where the specialized information may be further subdivided into widely useful specialized information and specific, or detailed, specialized information, a repeatedly used overlay containing the Widely useful specialized information is first fabricated; and then a specific overlay containing the detailed specialized information is fabricated. The two or more overlays containing the specialized information of varying degrees of general interest are then accurately aligned and the photographic reproduction overlay containing all of the specialized information from all of the overlays is prepared. Finally, the basic map and the photographic reproduction overlay are accurately aligned and are bonded together.

In the -rst step, a basic map is prepared by assembling a pictorial representation of a predetermined area; for example, an area encompassing a plurality of states. The pictorial representation may be aerial photographs directly; they may be other maps such as U.S. Geodetic Survey maps prepared from aerial photographs; or they may be other pictorial representations prepared from official compilations. The pictorial representation may be a large layout occupying a planar surface several feet in length and Width. In any event, predetermined general information from the pictorial representation is reproduced. The reproduction may be by a photographic reproduction in which the scale is reduced to a more manageable size, or it may comprise a reproduction produced by a draftsman or illustrator. Typically, on maps the reproduced predetermined general information Will include locations of a plurality of cities within each state and an interconnecting network of good highways.' Other information may be included if desired. In combination with this basic map containing general information it may be desired to employ additional specialized information such as advertising notations, mileages from a given city to the respective other cities for planning of routings and charges; which might be useful to trucking concerns, moving companies and the like; or rate information; which might be useful to a telephone or telegraph company.

I have found it advantageous to ascribe a code number to each state and to each city Within each state in order to expedite correlation of mileages from a predetermined .city to the respective other cities on the map. To illustrate, I have found it useful to make a map of the United States and to employ 616 major cities scattered throughout the states. |Each city will have an individual card, similar to that illustrated in FIG. 8. All

of the cards will have a code number given each state such as, the numeral 2 given Arizona in FIG. 8; and a code number given each city within that state for example, the numeral -2 given the city of Douglas in FIG. 8. Using the best available information, mileages are shown from the given city to each of the remaining cities shown on that card for the given city. The city is designated, for example, by the code number inserted in the blank labelled NO. and is named in the blank captioned mileages fromz (FIG. 8). Accordingly, when a map is desired containing mileages with respect to a given city the information is readily available for employment as described hereinafter.

The second step of preparing the photographic reproduction overlay containing the specialized information comprises a plurality of steps. First, an art work is prepared. The art work may include a plurality of information spots, that will contain the desired information. For example, each information spot may include a city designation, a blank for mileage, and a lead line that will terminate at a point overlying the city on the basic map. The necessity for the lead line to terminate at a point overlying the city on the basic map establishes a requirement that the art work be accurately aligned with the basic map. The art work may be simply black lines on white translucent paper.

Secondly, a plurality of photographic positives are made of the art work. Ordinarily, an expeditious Way of making the photographic positive comprises making, by contact photography, a photographic negative and making, by contact photography, a photographic negative and making, by contact photography, a photographic positive from the photographic negative. As is Well known, contact photography is simply the process of positioning the sheet containing the photographic emulsion adjacent the item to be copied and shining light through the item to be copied. The photographic emulsion is then developed by standard photographic techniques, the exact nature of which will depend upon whether the emulsion is a silver nitrate emulsion or other emulsion used in what is termed black and White photography or is an emulsion for color processes. Ordinarily, the black and white process is adequate for use in preparing the overlays. It is not necessary to delineate herein the details of the development of the photographic emulsions, whether black and white or color, since these are well known. These photographic positives then contain specialized information that is nonetheless widely useful. Accordingly, the photographic positives will be used repeatedly. A partial plan view of a typical photographic positive is illustrated in FIG. l. Therein, shown in black on the transparent photographic positive are city designation 11; a blank 13 for emplacement of the specific mileage information; and lead lines I15 terminating at a point that will overlay the city on the basic map, the photographic positive therefore must preserve the accurate alignment that the art work had with the basic map.

A plurality of photographic positives of FIG. l are prepared. On one of the photographic positives, the respective blanks for mileages are blacked in so as to form an insert into which the mileages can be placed when a photographic negative is made of the photographic positive. Respective code numbers for each state and for each city Within each state are also marked onto the photographic positive to expedite correlation of the mileages and cities. While it is not necessary, it is preferred that the lead lines 15 be erased from this photographic positive, since absence of lead lines tends to eliminate confusion. An accurately aligned photographic negative is made of the resulting modied photographic positive. For example, the photographic negative 17 of FIG. 2 contains mileage blanks 13 and code designations 19 for the respective cities, as well as the names of the cities. The photographic negatvie is emplaced on a planar surface such as a light table exposing the mileage blanks, the

code numbers, and the means of the cities. If desired, the names of the cities can be blanked out but this is not necessary and requires additional work. A sheet of transparent material is emplaced over and by suitable registration indicia in accurate alignment with the photographic negative on the light table. The sheet of transparent material may be a sheet of plastic material. Ordinarily, the thermoplastic materials have been found to be particularly satisfactory. These include polyethylene; polypropylene; poly(methyl methacrylate), commonly called Plexiglass: poly vinyl acetate; cellulose acetate, polystyrene, poly(styreneacrylonitrile), and others. Other transparent materials can be employed if desired.

As indicated hereinbefore, when a client desires a map having the mileages with respect to a given city, the card for that city is pulled and copies made of both sides of the card. The copies are sent to the printer. The printer then makes a list of the mileages from the predetermined city to the respective cities, the list of mileages being correlated so that each citys code number and respectlve mileages are on the same line and adjacent each other on the list and under the major code number for the state. FIG. 3 illustrates a list of mileages 21 and 23 correlated with the respective code numbers 19. The code numbers of 02 and 07 indicate respectively Camden and Trenton in the state of New Jersey, which has been arbitrarily given the code designation 28. Each mileage is on a transparent tab that is physically detachable from the list. When the list is received from the printer and after the transparent material has been placed over the photographic negative on the light table, the respective mileages are detached from the list and are inserted on the transparent material above the correlated blank in accordance with the respective code designations. FIG. 4 illustrates the sheet of transparent material 24 having the mileages 21 and 23 correlatably emplaced thereupon.

The transparent material having the respective mileages thereon is removed from above the photographic negative and accurately aligned with another of the photographic positives. A second photographic positive is prepared of the combined photographic positives for use as a photographic reproduction overlay. FIG. 5 illustrates a portion of the nal photographic reproduction overlay having in each information spot the city designation, the mileage 21 from the respective city to a predetermined city and the lead line 15 that will terminate above the spot on the basic map corresponding to the city.

By combining the photographic positive containing the more widely useful specialized information and the photographic positive containing the specific specialized information, each information spot will contain city designation, mileage from that city to the predetermined city and the lead line that will terminate above the spot on the basic map corresponding to the city. The photographic reproduction overlay, consisting of the second photographic positive may be prepared by any appropriate method. It has been found particularly satisfactory to employ contact photography as delineated hereinbefore to first prepare a photographic negative and then prepare a photographic positive from the resulting negative. Finally, the basic map and the photographic reproduction overlay, or second photographic positive, are accurately aligned and bonded together. As illustrated in FIG. 6 the accurate alignment may be effected by emplacing basic map 27 in a frame using aligning pins 29 to effect accurate alignment. The photographic reproduction overlay is emplaced in a frame 31 which is also a vacuum frame having a connection 33 for connecting with a vacuum pump or other source of vacuum. The photographic reproduction overlay 25 is emplaced in the frame, using aligning pins 3S if desired, and retained in place by the partial vacuum via frame 31. Glue is substantially uniformly applied to the information-containing side of basic map 27. Frame 31 is moved about its pivot point to bring the photographic reproduction overlay into accurate alignment with basic may 27. The vacuum is released on frame 31 allowing the basic map and the photographic reproduction overlay to be bonded together in accurate alignment. Thereafter, a pressure is applied uniformly to bond the basic map and the photographic reproduction overlay together eliminating any air pockets, or bubbles, that might otherwise be formed in the glue therebetween. FIG. 7 illustrates a partial plan view of the finished product. Thereon respective dots or circles 37 and highways 39 are contained on the basic map along with appropriate highway designations 41. The material on the basic map may be colored; for example, red and blue lines on a green background. On the overlay are information spots 43 containing the city designation, the respective mileage` from the predetermined city to the respective city and the lead line terminating above the spot 37 corresponding to the respective city. Items in the information spots are, ordinarily, black; although any color could be employed that would contrast with the basic map. For planning a move or routing to a particular city, the truck driver or dispatcher need only glance at the map for the respective city to have the mileage accurately delineated for him. Accordingly, charges can be rapidly calculated 0r the list of highways rapidly chosen. In the event delivery must be made to a town other than one of the major cities accurately pinpointed on the map, an overlay may be prepared for use with a nearby city that is shown on the map to delineate the mileage to the town. Mileage can be scaled off or otherwise calculated and the overlay iiled for future reference. Consequently, it can be seen that the map becomes increasingly advantageous to its user.

I have found that alignment is facilitated if the aligning pins are retractable so that they retract as the frame is swung into position. While the aligning pins are indicated as being in the surface of the map and the photographic reproduction overlay, they can merely be employed to align with marks or notches in the edge thereof. Any method; such as, employing marks as registration indicia; which will effect accurate alignment can be employed instead of the aligning pins.

Where the map is to be employed in general usage, it has been found preferable to bond the map via its back side to a relatively inexible planar support means. For example, a pivotally mounted frame similar to that illustrated in FIG. 6 may be employed and a piece of the relatively planar support means; such as, plyboard or Masonite; emplaced in one member of the frame. The basic map is emplaced in the other member such that its back side will contact the support means. Glue is applied substantially uniformly over the support means and the map swung into position, as described hereinbefore, in accurate alignment with the support means such accurate alignment facilitates subsequent alignment when the photographic reproduction overlay is emplaced in alignment with and bonded to the information-containing side of the basic map. Thereafter the map has a uniform pressure applied to it to eliminate air pockets, or bubbles, in the glue bonding it to its support means.

It has been found preferable that when photographic positives or photographic negatives are employed that the photographic emulsion be on the back side. By back side is meant the side away from the front of the material that will be in contact with personnnel. For example, the back side of the photographic repraduction overlay is the information-containing side that is bonded to the information-containing side of the basic map. In this way scratching of the photographic emulsion is prevented as the map is used in an oce. For example, overlays may be emplaced on a map and tracings made without scratching the emulsion.

In a finished map for hanging on the Wall it is frequently preferable to employ a frame around the map, the support means, and the photographic reproduction overlay. If desired, an additional sheet of transparent material such as glass or Plexiglass may be incorporated in the frame. This is ordinarily not necessary unless extraordinarily heavy usage by unskilled personnel is contemplated.

Thus, it can be seen that in one broad aspect, the invention provides a method of making an integral planar structure having a total information content composed of general information and specialized information. The method comprises the steps of preparing a planar first layer containing the general information; preparing a photographic reproduction overlay containing the specialized information and otherwise transparent over most of its area to expose the planar first layer; and accurately aligning and bonding together the photographic overlay and the planar rst layer. By the use of the photographic reproduction overlay and if necessary, a succession of overlays having information of varying degrees of general interest, economical integral planar structures can be prepared.

In another broad aspect the invention provides integral planar structures having laminated together a planar first layer containing the general information and a photographic reproduction overlay containing the specialized information, accurately aligned With each-other to effect a highly useful resulting laminated structure. In a specific embodiment the invention provides a basic map having predetermined cities and highways thereon, a photographic reproduction overlay of a photographic positive having a plurality of city designations and mileages thereto from a predetermined city and having the information-containing sides of the basic map and the photographic reproduction overlay bonded together to afford a working surface of the resulting laminated map. It has been found desirable to have the map and the photographic reproduction overlay bonded to a relatively inflexible planar support means in order that it may be hung on a wall to facilitate its use.

Although the invention has been described with a certain degree of particularly, it is understood that the present disclosure has been made only by Way of example and that numerous changes in the details of construction and combination and arrangement of parts may be resorted to without departing from the spirit and the scope of the invention.

What is claimed is:

1. A method of making a map containing general infofrmation and specialized information comprising the steps o (a) preparing a basic map containing said general information including locations of a plurality of cities within each state;

(rb) ascribing a code number to each said state and to each said city within each said state to expedite correlation of mileages and cities;

(c) preparing an art work including a plurality of information spots, each information spot including a city designation, a blank for mileage, and a lead line; said art work being accurately aligned such that said lead line terminates above the spot on said basic map corresponding to said city;

(d) making a plurality of photographic positives of said art work;

(e) on one of said photographic positives of step (d),

blacking in the blank for mileages, inserting the respective code numbers for each said state and each said city; and making a photographic negative of the resulting modified photographic positive;

(f) emplacing said photographic negative on a planar surface exposing said mileage blanks and said code numbers;

(Ig) emplacing above and in accurate alignment with said photographic negative a sheet of transparent material;

(h) making a list of mileages from a predetermined city to respective said cities, said list being correlated so each said citys code number and respective mileage are clearly delineated, said mileage being on a transparent tab that is physically detachable from said list;

|(i) detaching said respective mileages from said list and inserting them on said transparent material above the correlated `blank in accordance with the respective code designations;

(j) removing said transparent material having said respective mileages thereon from above said photoygraphic negative, accurately aligning said transparent material in registration with another of said photographic positives of step (e) and preparing, for use as a photographic reproduction overlay, a second photographic positive containing in each information spot city designation, mileage from said city to said predetermined city and the lead line that will terminate above the spot on said basic map corresponding to said city; and

(k) preparing a finished map containing all of the information on said basic map and said second photographic positive; said information being combined in accurate alignment.

2. The method of claim 1 wherein said accurately aligning before bonding is performed lvia registration indicia and a piwotally mounted frame that effects accurate alignment of the planar photographic reproduction overlay and the rbasic map.

3. The method of claim 1 wherein said bonding is effected -by gluing.

4. The method of claim 1 wherein said accurately aligning of said transparent material and said photographic positive is effected via registration indicia and a vacuum frame.

5. The method of claim 1 wherein said second photographic positive is effected by first preparing Via contact photography a negative having the photographic emulsion on its back side and then preparing via contact photography a photographic positive.

6. The method of claim 1 wherein a sheet of clear flexible plastic is employed as said transparent material.

7. The method of claim 1 wherein the informationcontainin-g side of said basic map is bonded to the photographic emulsion containing said specialized information on said second photographic positive.

8. The method of claim 1 wherein said basic map is also bonded via its back side to a relatively inflexible planar support means.

9. The method of claim 8 wherein the completed structure of said support means, said basic map, and said photographic reproduction overlay is mounted in a frame for convenient use.

10. A method of making a map containing general information and specialized information comprising the steps of:

(a) preparing a basic map containing said predetermined general information;

(b) preparing a photographic reproduction overlay containing said specialized information by the steps of:

(l) fabricating a repeatedly used overlay containing widely useful specialized information;

(2) fabricating a specific overlay containing detailed specialized information; and

(3) accurately aligning said repeatedly used overlay and said specific overlay and preparing a photographic reproduction overlay containing all of said specialized information from both overlay;

(c) accurately aligning and bonding together said basic map and said photographic reproduction overlay.

11. The method of claim wherein said preparing of said basic map comprises the steps of:

(a) assembling a pictorial representation of a predetermined area; and

(b) reproducing predeterminind general information from said pictorial representation to form said `basic map.

12. The method of claim 10 wherein said predetermined general information comprises location of a plurality of cities and towns and a plurality of highways; said repeatedly used overlay is a photographic positive containing a plurality of information spots, each information spot including a city designation, a blank for mileage, and a lead line terminating above the spot on said basic map corresponding to said city; said specific overlay comprises a transparent sheet containing respective mileages for respective said cities with respect to a predetermined city; and said photographic reproduction overlay is a photographic positive of all of the information on said repeatedly used overlay and said specific overlay.

13. The method of claim 12 wherein said specific overlay is prepared by the steps of:

(a) drafting an art work including a plurality of said information spots;

(b) making a plurality of photographic positives of said art work;

(c) on one of said photographic positives of step (b) |blacking in the blanks for the mileages and making a photographic negative of the resulting modified photographic positive;

(d) emplacing said photographic negative on a planar surface exposing said mileage blanks;

(e) emplacing above and in accurate registration with said photographic negative a sheet of transparent material;

(f) forming on said transparent material above respective said blanks the respective mileages from respective cities to a predetermined city;

(g) removing said transparent material having said respective mileages from above said photographic negative, accurately aligning said transparent material with another of said photographic positives of step (b) and preparing, for use as a photographic reproduction overlay, a second photographic positive containing in each information spot city designation, mileage from said city to said predetermined city and the lead line that will terminate above the spot on said basic map corresponding thereto.

14. 'I'he method of claim 13 wherein the lead line is erased from said photographic positive in making said modified photographic positive and before said photographic negative is made.

15. The method of claim 13 wherein a unique code number is inscribed onto said photographic positive for each said predetermined city within each said state in preparing said modified photographic positive Ibefore making said photographic negative.

16. The method of claim 1 wherein said step of preparing said finished map comprises the steps of accurately aligning and bonding together the basic map and the photographic reproduction overlay comprising the second photographic positive.

References Cited UNITED STATES PATENTS 666,788 1/ 1901 Aberli 35--40 1,611,868 12/1926 Alkire 156-63 1,869,839 8/1932 Boulard 156-62 2,503,126 4/1950 Muldrow III et al. 35-40 3,23 8,857 3/ 1966 Henderson 283-34 2,494,536 1/ 1950 Atwood 35--40 903,531 11/1908 Aberle 35-40 SAMUEL FEINBERG, Primary Examiner H. I. TUDOR, Assistant Examiner USS. Cl. X.R. 

